Guide assembly and method

ABSTRACT

A method of engaging a fastener may include attaching a guide assembly to a structure. The guide assembly may include a first arm, a second arm, and a head assembly mounted to an end of the first arm. The method may further include threadably engaging a tool sleeve to the head assembly, coupling a tool to the tool sleeve, and adjusting and clamping the angular orientation of the second arm relative to the first arm using a swivel mechanism. The method may additionally include engaging the tool to a fastener, rotating the tool sleeve relative to the head assembly, and applying a down force to the fastener in response to rotating the tool sleeve to move the tool axially relative to the head assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

(Not Applicable)

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

(Not Applicable)

FIELD

The present disclosure relates generally to fastener removal and, moreparticularly, to mechanisms adapted for removal of threaded fasteners.

BACKGROUND

During the inspection, repair and replacement of various components ofan assembly, it may be necessary to remove one or more fastenersattaching a component to a mating structure. Unfortunately, certainfasteners may be difficult to remove due to the buildup of corrosionaround the fastener hole which may bond or freeze the fastener in placeover time. Sealants and coatings applied to the fastener afterinstallation may also bond the fastener in place preventing removal ofthe fastener in a conventional manner using conventional tools.

For example, attempts to remove a machine screw that is frozen in placeby engaging a screwdriver to a tool recess of the screw head may resultin stripping out or deforming the tool recess and preventing furtherengagement thereof with the screwdriver. Attempts to remove a bolt thatis frozen in place by engaging a box-end wrench or an open-end wrench tothe bolt head may result in deforming or rounding off of the bolt headand eliminating the ability to further engage the wrench to the bolthead. In addition, attempts to remove a bolt that is frozen in place mayresult in shearing off of the bolt head at the surface of the structureleaving only the bolt shaft embedded in the structure.

Prior art solutions for removing frozen fasteners include the use ofscrew extractors which have sharpened flutes or teeth running along alength of the screw extractor. The teeth of such screw extractors aretypically manually driven into an engagement hole that is drilled intothe stripped fastener head or into the remaining shaft portion of thefastener. The engagement hole must be slightly smaller in diameter thanthe outer diameter of the screw extractor such that as the screwextractor is driven into the engagement hole, the teeth of the screwextractor can become sufficiently embedded into the inner diameter ofthe engagement hole. Once the screw extractor is sufficiently engaged tothe engagement hole, a wrench or ratchet may be applied to a free end ofthe screw extractor and the fastener may be rotated and removed from thestructure.

In order to avoid damage to the threaded bore into which the frozenfastener is installed, it is typically necessary that the engagementhole is generally aligned with the fastener. For example, for smalldiameter fasteners, to avoid drilling the engagement hole out of theside of the fastener shaft and damaging the threaded bore, thecenterline of the engagement hole must be generally aligned with thecenterline of the fastener. In addition, it is typically necessary thatthe engagement hole is centered on the fastener head or on the fastenershaft to avoid damage to the threaded bore.

A further requirement associated with the use of conventional screwextractors is that a sufficient amount of down force must be applied tothe screw extractor in order to drive the screw extractor into theengagement hole such that the teeth of the screw extractor can becomesufficiently embedded into the inner diameter. In this regard,incomplete or insufficient engagement of the screw extractor teeth intothe engagement hole can result in stripping out of the engagement holewhen rotating the screw extractor. Furthermore, in certain applications,it may be necessary to apply a down force to the screw extractor whilesimultaneously rotating the screw extractor during removal of thefastener to prevent the teeth of the screw extractor from becomingdisengaged from the engagement hole which may result in stripping outthe engagement hole.

The effectiveness of conventional screw extractors in removing frozenfasteners is dependent in part upon the skill of the operator both informing the engagement hole in alignment with the fastener and inapplying a sufficient amount of down force to engage the teeth of thescrew extractor into the engagement hole. Performing such operations inthe field adds complexity to the task and reduces the effectiveness ofconventional screw extractors in removing certain fastenerinstallations. For example, it may be necessary to remove a frozenfastener from an area that is difficult to access or which requiresdrilling an engagement hole in the fastener at an awkward angle. Inaddition, the fastener may be installed in a contoured surface making itdifficult to determine the proper orientation for positioning a drillgun such that the drill bit is aligned with the fastener centerline.

As can be seen, there exists a need in the art for a system and methodfor removing a fastener that facilitates forming an engagement hole in afastener and wherein the engagement hole is aligned with and centered onthe fastener. Furthermore, there exists a need in the art for a systemand method for removing a fastener wherein a sufficient amount of downforce may be applied to the screw extractor in order to drive the screwextractor teeth into engagement with the engagement hole. Additionally,there exists a need in the art for a system and method for removing afastener from a structure wherein the alignment of the screw extractormay be maintained while continuously applying a down force to the screwextractor during removal of the fastener. Finally, there exists a needin the art for a system and method for removing a fastener wherein theabove-described alignment and down force requirements may be applied tofasteners installations in contoured surfaces.

SUMMARY

The above noted needs associated with extraction of frozen fasteners arespecifically addressed and alleviated by the present disclosure whichprovides a guide assembly that may be mounted to a structure or aworkpiece and which is adapted for removing fasteners from thestructure. The guide assembly may comprise a frame assembly, a pluralityof clamping assemblies mounted to the frame assembly and a head assemblymounted to the frame assembly. In an embodiment, the frame assembly mayinclude first and second arms which may be adjustably positionablerelative to one another to facilitate attachment of the frame assemblyto the structure. The clamping assemblies may be mountable to the frameassembly and may be orientatable relative thereto to facilitateattachment of the frame assembly to the structure. The clampingassemblies may be provided in a variety of alternative configurationsincluding, but not limited to, vacuum cup assemblies and magnetassemblies. The frame assembly may also be secured in position relativeto the structure without the aid of vacuum cup assemblies, magnetassemblies or mechanical attachment. For example, the frame assembly maybe configured to be manually held in position against the structure. Theguide assembly may further include the head assembly which may bemounted to the frame assembly. The head assembly may optionally be usedindependent of the frame assembly. For example, the head assembly may beremovably secured to tooling that may be independent of the structureand wherein the tooling may maintain the head assembly in positionrelative to the structure.

The head assembly may include a removable tool. Notably, the tool may beaxially movable relative to the head assembly in order to cause the toolto exert a down force on the fastener when the frame assembly isattached to the structure. The tool may be provided in a variety ofdifferent configurations. For example, the tool may be configured as ascrew drive bit for engaging a fastener. In this regard, the screw drivebit may be configured as a fastener bit for engaging a tool recessformed in the fastener. The screw drive bit may also be configured as anextractor bit for extracting fasteners which may be frozen in positionin the structure. In addition, the screw drive bit may comprise afastener bit such as a Phillips head drive, a slotted drive, a Torxdrive, an Allen drive (i.e., internal hex), a socket drive (i.e.,external hex) or any one of a variety of alternative internal andexternal drive configurations for engaging an internal or externalfeature of a fastener head. The tool may also be configured as a drillguide for drilling an engagement hole in a fastener or drilling afastener hole in the structure.

Advantageously, the head assembly may include an alignment mechanismincluding a bearing assembly such as a spherical bearing for providingadjustability of an orientation of the tool relative to the frameassembly. In this regard, the alignment mechanism may facilitatealignment of the tool (e.g., drill guide) with an axis or centerline ofa hole in the structure. In addition, the alignment mechanism mayfacilitate alignment of the tool with a centerline of a fastener towhich the tool (e.g., extractor bit, screw drive bit) may be engaged. Inan embodiment, the alignment mechanism may comprise a bearing assemblyincluding a spherical bearing which may be rotatably contained ormounted within a bearing collar contained or housed within a head bodyof the head assembly.

The head assembly may include a mechanism by which the position of thealignment mechanism may be fixed following adjustment of the orientationthereof. In this manner, the tool may be axially and positionablyaligned with the fastener and/or with a hole after the frame assembly isattached or mounted to the structure. The down force may be applied bythe head assembly by means of rotating a tool sleeve which may bethreadably coupled to the head assembly. Rotation of the tool sleeve mayresult in axial movement of the tool relative to the head assembly. Forexample, rotation of the tool sleeve in a clockwise direction may resultin movement of the tool away from the head assembly. When the frameassembly is mounted to the structure, movement of the tool away from thehead assembly (i.e., toward the structure) results in the application ofthe down force to the fastener to which the tool may be engaged.

In an embodiment, the frame assembly may include first and second arms.At least one of the first and second arms may have at least one of theclamping assemblies adjustably mounted thereto. Furthermore, each one ofthe clamping assemblies may be rotatably or orientatably positionablerelative to the first and second arms to which each one of the clampingassemblies may be mounted. The frame assembly may further include aswivel mechanism which may interconnect the first and second arms. Theswivel mechanism may be configured such that an orientation of the firstand second arms is adjustable relative to one another. In this manner,the first and second arm may be oriented in an optimal position relativeto one another to facilitate attachment of the guide assembly to avariety of different structure configurations.

The alignment mechanism may include the tool sleeve which may be sizedand configured to receive a drill guide. The drill guide may be sizedand configured to be inserted or mounted within the tool sleeve. In thisregard, the drill guide may be removably installable within the toolsleeve and may include a drill bore that may be sized and configured toreceive a drill bit. The drill bit may be used for drilling anengagement hole in the fastener and/or for drilling a fastener hole inthe structure at a predetermined hole location. In an alternativeembodiment, the tool sleeve may comprise the drill guide such that thedrill guide is directly engaged to the alignment mechanism.

The present disclosure also includes a method of engaging a fastenermounted or installed in the structure. The method may comprise the stepsof attaching the guide assembly to the structure followed by insertingthe drill guide into the tool sleeve. The tool sleeve may be alignedwith the fastener by rotating the spherical bearing until the toolsleeve is substantially aligned with a fastener axis of the fastener.The methodology may further include drilling the engagement hole in thefastener followed by removal of the drill guide from the tool sleeve andinstallation of a drive member in the tool sleeve. The drive member maycomprise a drive shaft that may be sized and configured to be rotatablewithin the tool sleeve.

A tool such as a screw extractor bit may be coupled to an end of thedrive member. The tool (e.g., screw extractor bit) may be placed inengaging contact with the engagement hole of the fastener by axiallymoving the tool sleeve relative to the head assembly. For example, byrotating the threadably coupled tool sleeve into the head assembly, thetool may be non-rotatably and axially moved into engagement with theengagement hole of the fastener. By continuously moving the tool sleeveaxially relative to the spherical bearing (i.e., head assembly), a downforce may be applied to the tool in order to drive the tool (i.e., screwextractor bit) into the engagement hole of the fastener. Upon engagementof the screw extractor bit into the engagement hole, the fastener may beremoved by rotating the drive member. For example, for removing afastener having right-hand threads, rotation of the drive member in acounter-clockwise direction results in removal of the fastener from thefastener hole. In addition, by minimizing or preventing rotation of thetool sleeve when the drive member is rotated, a down force may becontinuously maintained on the fastener to maintain engagement of thetool within the engagement hole.

The features, functions and advantages that have been discussed can beachieved independently in various embodiments of the present disclosureor may be combined in yet other embodiments, further details of whichcan be seen with reference to the following description and drawingsbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the present disclosure will become moreapparent upon reference to the drawings wherein like numbers refer tolike parts throughout and wherein:

FIG. 1 is a top perspective illustration of an embodiment of a guideassembly shown as being attached to a structure or a workpiece andfurther illustrating a fastener to which a tool of the guide assemblymay be engaged for removal from the structure;

FIG. 2 is a bottom perspective illustration of an embodiment of theguide assembly illustrating a plurality of clamping assemblies mountableto a frame assembly of the guide assembly and further illustrating ahead assembly having the tool coupled thereto;

FIG. 3 is a top illustration of the guide assembly illustrating theclamping assemblies mounted on first and second arms of the frameassembly and further illustrating the head assembly mounted to the frameassembly;

FIG. 4 is a top illustration of an embodiment of the guide assemblywherein the clamping assemblies are configured as magnetic mechanismsfor magnetic attachment of the guide assembly to the structure;

FIG. 5 is a sectional illustration of one of the magnetic mechanismstaken along line 5-5 of FIG. 4 and illustrating one of the magneticmechanisms configured as an electromagnetic;

FIG. 6 is a side illustration of the guide assembly illustrating thetool of the head assembly engaged to the fastener;

FIG. 7 is a perspective illustration of the head assembly illustratingthe tool engaged to an alignment mechanism contained within a head bodyof the head assembly;

FIG. 8 is an exploded perspective illustration of the head assembly andillustrating the alignment mechanism configured as a bearing assemblyhaving a spherical bearing for adjusting an orientation of the toolrelative to the frame assembly;

FIG. 9 is a sectional illustration of the guide assembly taken alongline 9-9 of FIG. 3 and illustrating the interconnectivity of the variouscomponents which make up the head assembly and further illustrating aswivel mechanism for interconnecting the first and second arms of theframe assembly;

FIG. 10 is a sectional illustration of the head assembly having a drillguide inserted thereinto for receiving a drill bit to drill anengagement hole in the fastener;

FIG. 11 is a sectional illustration of the head assembly wherein thedrill guide is replaced with a drive member having the tool coupled toan end thereof for engaging the engagement hole that may be formed inthe fastener;

FIG. 12 is a sectional illustration of the head assembly illustratingrotation of the tool while a down force is applied thereto for removalof the fastener;

FIG. 13 is a sectional illustration of the head assembly illustrating aposition of the tool relative to the head assembly following removal ofthe fastener from a fastener hole;

FIG. 14 is a sectional illustration of the head assembly having a drillguide in contacting engagement with the structure for applying a downforce to the structure during drilling of a fastener hole in thestructure;

FIG. 15 is a methodology of engaging a fastener using the guideassembly;

FIG. 16 is a methodology of drilling a fastener hole in the structureusing the guide assembly;

FIG. 17 is a methodology of engaging a fastener mounted in thestructure;

FIG. 18 is a flow diagram of an aircraft production and servicemethodology; and

FIG. 19 is a block diagram of an aircraft.

DETAILED DESCRIPTION

Referring now to the drawings wherein the showings are for purposes ofillustrating preferred and various embodiments of the disclosure onlyand not for purposes of limiting the same, shown in FIGS. 1-6 is a guideassembly 10 in an embodiment as may be used for removing fasteners 166from a structure 168. In addition, the guide assembly 10 may be employedfor drilling fastener holes 176 in the structure 168 by orienting adrill bit 164 into alignment with the structure 168 and/or maintainingalignment while drilling the fastener hole 176. Toward this end, thehead assembly 50 may include an alignment mechanism 102 for adjusting anorientation of a tool 110 that may be coupled to the alignment mechanism102. The tool 110 may be provided in a variety of configurationsincluding, but not limited to, a screw drive bit 128 for engaging afastener 166.

The tool 110 may be also configured as a drill guide 130 having a guidebore 132 for guiding a drill bit 164 as may be used for drillingfastener holes 176 in the structure 168 or drilling engagement holes 178in a fastener 166 that may be frozen in place in the structure 168. Upondrilling the engagement hole 178 in the fastener 166, the drill guide130 may be removed from the alignment mechanism 102 and a screw drivebit 128 or screw extractor bit may be mounted to the head assembly forengaging the engagement hole 178 such that the fastener 166 may beremoved. Advantageously, the guide assembly 10 is configured to apply adown force to the tool 110 to force the extractor bit into theengagement hole 178 such that the fastener 166 may then be rotatablyremoved from the structure 168.

As can be seen in FIGS. 1-6, the guide assembly 10 may comprise a frameassembly 12, a plurality of clamping assemblies 34 and a head assembly50. In an embodiment, the frame assembly 12 may include first and secondarms 14, 16 which may be adjustably positioned relative to one anotherin order to facilitate mounting of the guide assembly 10 on a widevariety of structures 168 of varying sizes, shapes and configurations.For example, the guide assembly 10 may be configured to facilitateattachment of the frame assembly 12 to one or more portions of thestructure 168 or to one or more surfaces 170 of the structure 168. Suchsurfaces 170 may include planar surfaces, contoured or curved surfaces,or any combination thereof.

The guide assembly 10 may include the plurality of clamping assemblies34 which may be provided in a variety of different configurations forattaching the guide assembly 10 to the structure 168 such as to asurface 170 of the structure 168. For example, in a preferredembodiment, the clamping assemblies 34 may be configured as one or morevacuum cup assemblies 42. Each one of the vacuum cup assemblies 42 mayinclude one or more vacuum cups to which a vacuum may be applied inorder to secure the guide assembly 10 to the surface 170. The vacuum cupassembly 42 facilitates attachment of the guide assembly 10 to contouredor curved surfaces. In this regard, the guide assembly 10 is adapted forfield operations including maintenance and repair operations away from aproduction or assembly facility. For example, the vacuum cup assembly 42may facilitate attachment of the guide assembly 10 to a contouredsurface 170 of an aircraft for removal of fasteners 166 and/or fordrilling fastener holes 176.

However, as may be appreciated, the guide assembly 10 may be used in avariety of different applications and industries and on different typesof structure and is not limited for use with aircraft assemblies. Inthis regard, the guide assembly 10 may be used for engaging fasteners166 and/or for drilling fastener holes 176 in any vehicular ornon-vehicular application including any system, subsystem, assembly,subassembly, apparatus or environment. Furthermore, the guide assembly10 may be used in any operation where alignment of a tool 110 with astructure 168 and/or a surface 170 thereof is desired. In this regard,the guide assembly 10 is not limited to facilitate aligning of a drillguide 130 with the structure 168 for drilling holes or for engaging ascrew drive bit 128 with a fastener 166.

Referring briefly to FIGS. 4-5, the clamping assemblies 34 may beconfigured as magnet assemblies 44 wherein each magnet assembly 44 maycomprise one or more magnets. The magnets may be configured as permanentmagnets and/or as electromagnets. The magnet assemblies 44 may beadapted to attach the frame assembly 12 to a structure 168 by magneticattraction to a ferrous or magnetically attractable material of thestructure 168. Further in this regard, the clamping assemblies 34 may beconfigured in a variety of alternative embodiments and are not limitedto the vacuum cup assembly 42 or magnet assembly 44 configurations. Forexample, each one of the clamping assemblies 34 may be configured as amechanical attachment mechanism (not shown) for mechanically couplingthe frame assembly 12 to a structure 168 such as by engaging surfacefeatures of the structure 168. For example, the structure 168 mayinclude fastener or non-fastener elements to which the frame assembly 12may be configured to engage. Even further, it is contemplated that theclamping assemblies 34 may comprise non-mechanical means for attachingthe frame assembly 12 to the structure 168. For example, the clampingassemblies 34 may be configured to releasably bond the frame assembly 12to the structure 168.

It is further contemplated that the frame assembly 12 may be configuredto be held in place against a structure 168 such as by a techniciangrasping a portion of the frame assembly 12 and urging the frameassembly 12 toward the structure 168. The frame assembly 12 may beprovided in a configuration that facilitates grasping of the device byone or more technicians. The frame assembly 12 may be held in positionduring use of the head assembly 50 to remove a fastener 166 or to drilla fastener hole 176 or an engagement hole 178. For example, the frameassembly 12 may be configured to manually held or secured in positionagainst the structure 168 by a technician without the aid of vacuumforce applied through vacuum cup assemblies 42. Likewise, the frameassembly 12 may be configured to manually held or secured in positionagainst the structure 168 by a technician without the aid of magneticforce acting through magnet assemblies 44. The frame assembly 12 mayalso be configured to be held in position without the aid of mechanicalattachment of the frame assembly 12 to the structure 168 and/or withoutthe aid of releasably bonding the frame assembly to the structure 168.

In this regard, it is contemplated that the head assembly 50 may be usedindependent of the frame assembly 12. For example, the frame assembly 12may be configured as a hand held device (not shown) which may be graspedand held in place by a technician while another technician uses the headassembly 50 to remove a fastener 166 or to drill a fastener hole 176 orengagement hole 178 in a manner described below. A portion of such ahand held device may optionally be placed in contact with a portion ofthe structure 168 as a means to index the head assembly 50 relative tothe structure 168. It is further contemplated that the head assembly 50may be secured to a separate fixture (not shown) that may be independentof the head assembly 50 and may also be independent of the structure 168being operated upon. For example, the head assembly 50 may bepermanently or releasably secured to one or more tooling arms or toolingfixtures (not shown) that are separate from the structure 168. Suchtooling arms or tooling fixtures may provide a means to position thehead assembly 50 relative to the structure 168.

Referring to FIGS. 1-6, each one of the clamping assemblies 34 may beconfigured to be adjustably orientatable relative to the frame assembly12 to facilitate mounting of the frame assembly 12 to one or more planarsurfaces and/or contoured surfaces. Toward this end, each one of theclamping assemblies 34 may be configured to be pivotably adjustable orrotatable about the first or second arm 14, 16 to which the clampingassembly 34 is mounted as described in greater detail below. The guideassembly 10 may further include the head assembly 50 which may befixedly mounted to the frame assembly 12 and which may include the tool110 in one or more configurations. The tool 110 may be configured to beaxially movable relative to the head assembly 50 to facilitate theapplication of the down force by the tool 110 onto the surface 170.Axial movement of the tool 110 may also facilitate the application ofthe down force to a surface feature 182 of the structure 168. Suchsurface features 182 may comprise a fastener 166 such as a bolt or ascrew or any other threaded or non-threaded fasteners and includingnon-fastener elements which may be mounted to the structure 168.

The tool 110 may be configured as the screw drive bit 128 which may beprovided as a screw extractor bit for engaging a fastener 166 which maybe frozen or bonded to the structure 168 due to buildup of corrosion orsealant. The screw drive bit 128 may also be configured as a fastenerbit to engage a drive recess in the fastener 166 to allow forinstallation and/or removal of the fastener 166. The fastener bit may beconfigured as a Phillips head drive, slotted drive, Torx drive, Allendrive (i.e., internal hex), socket drive (i.e., external hex) or any oneof a variety of alternative internal and external drive configurationsfor engaging internal or external drive features of the fastener 166.

Advantageously, the head assembly 50 is adapted such that the tool 110is axially movable relative to the head assembly 50 to enable the tool110 to exert the down force on the structure 168 or surface 170 and/oron the fastener 166 when the frame assembly 12 is attached to thestructure 168 or surface 170. In this manner, the guide assembly 10facilitates the application of the down force against the fastener 166to maintain engagement of the screw drive bit 128 or fastener bit withthe fastener 166. In this regard, the down force minimizes the risk ofinadvertent disengagement of the tool 110 which may result in deformingor stripping of the internal (e.g., drive recess) or deforming externaldrive features such as an external hex fastener head of the fastener166.

Referring particularly now to FIGS. 1-3, shown is the frame assembly 12which, in an embodiment, may comprise the first and second arms 14, 16and including a swivel mechanism 18. The swivel mechanism 18 may providea means for interconnecting the first and second arms 14, 16 to oneanother. The swivel mechanism 18 may also be configured to provideadjustable positioning of the first arm 14 relative to the second arm16. For example, the swivel mechanism 18 may facilitate positioning thefirst and second arms 14, 16 into the cruciform position as shown inFIGS. 1-4 wherein the second arm 16 is oriented substantiallyperpendicularly relative to the first arm 14 such that a tube angleθ_(t) between the first and second arms 14, 16 is substantially 90degrees. In addition, the swivel mechanism 18 may facilitate adjustingthe first and second arms 14, 16 into a non-perpendicular orientationwherein the tube angle θ_(t) defines an acute angle. For example, FIG. 3illustrates the second arm 16 in phantom and positionednon-perpendicularly relative to the first arm 14. In this manner, theswivel mechanism 18 provides a means for adjusting the relativepositions of the first and second arms 14, 16 to facilitate mounting ofthe frame assembly 12 to a variety of different structure 168configurations.

Referring briefly to FIG. 9, shown is a cross-sectional illustration ofthe guide assembly 10 illustrating the swivel mechanism 18. In anembodiment, the swivel mechanism 18 may include a generally hollowswivel housing 20 containing an upper fitting 26, an intermediatefitting 28 and a lower fitting 30. Each one of the upper fitting 26,intermediate fitting 28 and lower fitting 30 may be slightly axiallymovable with the swivel housing 20. The second arm 16 may pass through apair of slotted openings 24 formed on diametrically opposed sides of theswivel housing 20. As shown in FIG. 9, the second arm 16 may be clampedbetween semi-cylindrical channels or other features that may be formedin the upper and intermediate fitting 26, 28.

Likewise, the first arm 14 may be clamped between a lower fitting 30 anda pair of swivel housing bores 22 formed on diametrically opposed sidesof the swivel housing 20. The first arm 14 may extend through the swivelhousing bores 22 allowing the first arm.14 to be axially positionedrelative to the swivel housing 20. For example, the first arm 14 may beslid through the swivel housing bore 22 to bias the length of the firstarm 14 to one side of the swivel housing 20 as distinguished from thegenerally equalized positioning of the first arm 14 relative to theswivel housing 20 illustrated in FIGS. 1-4. Adjustment of the relativepositions of the first and second arms 14, 16 may be facilitated byrotating the swivel handle 32. For example, by rotating the swivelhandle 32 in a clockwise direction, the second arm 16 may be clampedbetween the upper fitting 26 and the intermediate fitting 28 and thefirst arm 14 may simultaneously be clamped between the lower fitting 30and the swivel housing bores 22. Counterclockwise rotation of the swivelhandle 32 results in loosening or unclamping of the first and secondarms 14, 16 between the upper, intermediate and lower fitting 26, 28, 30to allow free rotation of the first arm 14 relative to the second arm 16and to also allow axial adjustment of each one of the first and secondarms 14, 16 along the respective lengths thereof.

Referring to FIG. 2, the swivel housing 20 may include a diametricallyopposed pair of slotted openings 24 as indicated above to facilitatepositioning or rotation of the second arm 16 relative to the first arm14. For example, as shown in FIG. 3, the second arm 16 may be rotatedfrom a 90 degree tube angle θ_(t) to a non-perpendicular tube angleθ_(t) as illustrated. Although the second arm 16 is illustrated asextending through the slotted openings 24 and the first arm 14 extendingthrough the swivel housing bores 22, the swivel mechanism 18 may beconfigured such that the second arm 16 extends through the cylindricalswivel housing bores 22 and the first arm 14 extends through the slottedopenings 24. In addition, it should be noted that the frame assembly 12is not limited to the arrangement shown in FIGS. 1-4 comprising firstand second arms 14, 16. For example, it is contemplated that the frameassembly 12 may be configured as a non-movable structure wherein thepositions of the arms are fixed relative to one another. In analternative embodiment, the frame assembly 12 may be configured withadditional arms and is not limited to the first and second arms 14, 16as shown in the illustrated embodiments. Even further, it should benoted that the frame assembly 12 may be configured in any configurationfor attaching the guide assembly 10 to the structure 168 such as to thesurface 170 of the structure 170. In addition, as described above, theguide assembly 10 may be configured to be maintained in position withoutattaching the frame assembly 12 to the structure 168.

Referring to FIG. 2, shown is a perspective view of the guide assembly10 illustrating an embodiment wherein the clamping assemblies 34 may beadjustably rotatable on the first and second arms 14, 16. In theembodiment shown, the second arm 16 may include a pair of clampingassemblies 34 located on opposing sides of the second arm 16 althoughany number of clamping assemblies 34 may be mounted to the second arm 16including a single one of the clamping assemblies 34. The first arm 14may include one or more clamping assemblies 34 although only a singleone of the clamping assemblies 34 is shown mounted to the first arm 14.Each one of the clamping assemblies 34 may be adjustably orientatablerelative to the arm to which they are mounted in order to facilitatealignment of the clamping assembly 34 with the structure 168 to whichthe frame assembly 12 may be mounted. In the embodiment shown, each oneof the clamping assemblies 34 may be mounted to the first and secondarms 14, 16 by means of a clamp mechanism 40. The clamp mechanism 40 maycomprise a clamp fitting 36 having a clamp handle 38 for clamping andunclamping of the clamp fitting 36 to the first and second arms 14, 16.

The clamp handle 38 may include a threaded shaft extending into athreaded bore formed in the clamp mechanism 40. The clamp fitting 36 mayinclude a spacing dividing the clamp fitting 36 into opposing sideportions. Rotation of the clamp handle 38 (e.g., in a clockwisedirection) causes relative axial motion of the opposing side portions ofthe clamp fitting 36 drawing the side portions together to clamp theclamp fitting 36 to the first arm 14 or second arm 16. Counterclockwiserotation of the clamp handle 38 disengages the clamp fitting 36 from thearm to which the clamp fitting 36 is mounted and allowing free rotationof the clamping assembly 34 relative to the arm. For example, as shownin FIG. 2, each one of the clamping assemblies 34 may rotate about anaxis of the first arm 14 or second arm 16 to which it is mounted. Inthis manner, each one of the clamping assemblies 34 may be adjusted inorder to be substantially aligned with a local area of the structure 168or surface 170 to which the frame assembly 12 is to be mounted. It isalso contemplated that the clamp fittings 36 may provide an additionaldegree of adjustability of the clamping assemblies 34 relative to thearms and is not limited to single-axis rotation about the axes of thearms. For example, although FIGS. 1-6 illustrate an embodiment whereinthe clamping assemblies 34 are mounted such that rotation of theclamping assemblies 34 is limited to a single axis, it is contemplatedthat the clamp mechanism 40 may be provided with an articulatedarrangement to facilitate rotation or adjustment of the clampingassemblies 34 about two or more axes to increase the ability tosubstantially align the clamping assemblies 34 with the local structure168 or surfaces 170 to which the clamping assemblies 34 may be mounted.

Referring briefly to FIG. 9, further adjustment of the positioning ofthe clamping assemblies 34 may be provided by a mounting shaft 41 tofacilitate axial or height adjustment of the clamping assemblies 34relative to the first or second arm 14, 16 to which the clampingassembly 34 is mounted. Such axial or height adjustment of the clampingassemblies 34 provides an additional measure by which the frame assembly12 may be adjusted to be complementary to a structure 168 or surface 170to which the frame assembly 12 may be mounted. By rotating the shaftand/or by rotating the clamping assembly 34 about the shaft, thedistance from the clamping assembly 34 to the arm may be adjusted. A jamnut may be provided on the mounting shaft 41 such that the axialposition of the clamping assembly 34 may be locked in place afteradjustment.

Referring still to FIGS. 1-6, in a preferred embodiment of the guideassembly 10, the clamping assemblies 34 may be configured as vacuum cupassemblies 42 for vacuum or suction attachment to one or more surfaces170 of the structure 168. Each one of the vacuum cup assemblies 42 maycomprise one or more vacuum cups which may be mounted to the firstand/or second arms 14, 16 by means of the clamp mechanism 40 asdescribed above. Although shown as having a generally circular shape,the vacuum cup assemblies 42 may be provided in any configuration andare not limited to the size, shape or configuration illustrated. Inorder to attach the vacuum cup assemblies 42 to the surface 170, vacuummay be provided to each one of the vacuum cup assemblies 42 by means ofone or more conduits 150 which may be interconnected at a manifold 148.Vacuum may be provided by a vacuum source 144 such as a compressor pump(not shown) or other suitable vacuum supply. The vacuum source 144 maybe fluidly connected to the guide assembly 10 by means of the fittingshown in FIG. 3 which may extend outwardly from a control module housing142 of a control module 140 of the guide assembly 10.

The control module 140 may house a variety of components for regulatingthe vacuum for distribution to each one of the vacuum cup assemblies 42.For example, the control module 140 may house components including, butnot limited to, sensors, regulators, filters, check and/or safety valvesand a variety of additional components that may be required foroperating the clamping assemblies 34. An activation switch 146 forregulating operation of the clamping assemblies 34 may be included withthe control module housing 142 to initiate the application of vacuum tothe vacuum cup assemblies 42. Deployment of the activation switch 146may cause a vacuum source 144 to apply a vacuum force to each one of thevacuum cup assemblies 42 through the conduits 150. Selective control ofeach one of the vacuum cup assemblies 42 may be provided by individualactivation switches 146 for each one of the vacuum cup assemblies 42such as the activation switch 146 mounted on the vacuum cup assembly 42of the first arm 14 as illustrated in FIG. 3.

Referring briefly to FIGS. 4-5, shown is an embodiment of the guideassembly 10 wherein the clamping assemblies 34 are configured as magnetassemblies 44 for facilitating magnetic attachment of the guide assembly10 to the structure 168. For example, one or more of the magnetassemblies 44 may be mounted on each of the first and/or second arms 14,16 as illustrated in FIG. 4 similar to that which is illustrated withrespect to the vacuum cup assemblies 42 of FIGS. 1-3. In an embodiment,each one of the magnet assemblies 44 may comprise one or more permanentmagnets. Alternatively, each one of the magnetic mechanisms may compriseone or more electromagnets 48. Each electromagnet 48 may be activated byapplying electric current to generate an electromagnetic field creatingattraction with ferrous or otherwise magnetically-attractable materialof the structure 168 in a manner known in the art.

As shown in FIG. 5, the magnet assemblies 44 may comprise theelectromagnet 48 configuration which may be electrically connected to apower source by suitable wiring 152 or other conductive means fordelivering electric current. The electromagnets 48 may be activated bydeploying the activation switch 146 which may be mounted on the controlmodule housing 142 and/or on each one of the magnet assemblies 44.Although shown as having a generally disc-shaped configuration, themagnet assemblies 44 may be provided in any size, shape andconfiguration. Furthermore, each one of the magnet assemblies 44 may beconfigured to be positonable or orientatable relative to the first orsecond arm 14, 16 to which they are mounted in a manner similar to thatwhich is described above with regard to the vacuum cup assemblies 42.

Referring now to FIGS. 6-14, shown is the head assembly 50 of the guideassembly 10. In an embodiment, the head assembly 50 may be fixedlymounted to the frame assembly 12 such as by mechanical attachmentutilizing one or more fasteners extending from an end of the first arm14 into a corresponding number of threaded bores formed in a head body52 of the head assembly 50 as shown in FIG. 7. The head assembly 50 isconfigured such that a tool 110 is axially movable relative to the headassembly 50 in order to cause the tool 110 to exert a down force onto astructure 168 or surface 170 or onto a fastener 166 to which the tool110 may be engaged. The down force may be applied as a result ofattachment of the frame assembly 12 to the structure 168 or surface 170by means of the clamping assemblies 34. The head assembly may be usedindependent of the frame assembly and the down force may alternativelybe applied as a result of attachment of the head assembly to separatetooling or fixtures (not shown) as described above.

As can be seen in FIGS. 7-8, the head assembly 50 may include a toolsleeve 96 which may be threadably coupled to the head assembly 50 suchthat rotation of the tool sleeve 96 results in axial movement of thetool 110. For example, clockwise rotation of the tool sleeve 96 mayresult in movement of the tool 110 away from the head assembly 50 whilecounterclockwise rotation of the tool sleeve 96 may result in drawingthe tool 110 toward the head assembly, depending upon the threadconfiguration coupling the tool sleeve 96 to the head assembly 50 (i.e.,left-hand threads or right-hand threads). As shown in FIG. 11, rotationof the tool sleeve 96 results in movement of the tool 110 toward thefastener 166 installed in the structure 168. Conversely, rotation of thetool sleeve 96 in a counterclockwise direction draws the tool 110upwardly toward the head assembly 50 and away from the fastener 166 asdescribed in greater detail below.

Referring to FIG. 8, the head assembly 50 may include an alignmentmechanism 102 in order to facilitate adjusting an orientation of thetool 110 relative to the frame assembly 12. The alignment assemblyprovides a means for orienting the tool 110 such that a tool axis 104 ofthe tool 110 may be aligned with a fastener axis 180 of the fastener166. The alignment mechanism 102 may also facilitate orienting the tool110 into alignment with a hole axis of a hole to be drilled at apredetermined hole location 184. In an embodiment, the alignmentmechanism 102 may comprise a bearing assembly 70 to facilitateadjustable orientation of a head angle θ_(h) of the tool 110 relative tothe frame assembly 12 as shown in FIGS. 6 and 9. For example, thebearing assembly 70 may comprise a spherical bearing 74 which may berotatably mounted within a bearing collar 72 as best seen in FIG. 8. Thebearing collar 72 may, in turn, be housed or contained within the headbody 52.

As shown in FIG. 8, the bearing collar 72 may include a slot 68 a at aradial position of the bearing collar 72 to facilitate clamping of thespherical bearing 74 at a desired orientation. Likewise, the head body52 may include a slot 68 b at a radial position thereof as shown in FIG.7 such that the spherical bearing 74 may be clamped into positionfollowing adjustment of an orientation of the tool 110. The headassembly 50 may include a head handle 54 having a threaded shaft 56extending into a threaded bore 58 formed in the head body 52. Rotationof the head handle 54 facilitates clamping or unclamping of the bearingcollar 72 around the spherical bearing 74. A spacer 60 may be receivablewithin the slots 68 a, 68 b formed in the head body 52 and the bearingcollar 72 to maintain the bearing collar 72 in position within the headbody 52. The threaded shaft 56 may extend through a hole in the spacer60 in order to retain the spacer 60 with the head assembly 50. Thespacer 60 may have a reduced thickness relative to a width of the slots68 a, 68 b such that the bearing collar 72 may be clamped around thespherical bearing 74. The spacer 60 may maintain the angular position ofthe slot 68 b in alignment with the slot 68 a to prevent rotation of thebearing collar 72 to a position that may limit the ability to clamp thebearing collar 72 around the spherical bearing 74.

To facilitate alignment of the head body 52 with the frame assembly 12,an alignment pin 64 may be provided with the frame assembly 12 whereinthe alignment pin 62 is insertable into a recess 66 formed in the headbody 52. The alignment pin 64 may extend outwardly from an end of theframe assembly 12 as shown in FIGS. 7-9 and may facilitate mounting ofthe head body 52 onto the frame assembly 12. As noted above, the headbody 52 may be fixedly mounted to the frame assembly 12 using one ormore mechanical fasteners extending from an end of the first arm 14 intoa corresponding number of threaded bores in the head body 52 as shown inFIG. 7. The alignment pin 64 may facilitate the substitution of oneconfiguration of the head assembly 50 with a different configuration ofthe head assembly 50 by maintaining alignment therebetween. In addition,the alignment pin 64 may facilitate the transfer of shear load betweenthe head assembly 50 and the frame assembly 12 as may occur duringapplication of the down force by the head assembly 50 onto a fastener166 during extraction thereof or during drilling of a fastener hole 176into the structure 168. As may be appreciated, a variety of differentmechanisms may be incorporated into the head body 52 to maintain thealignment of the head body 52 relative to the frame assembly 12.

Referring still to FIG. 8, the head assembly 50 may include the bearingcollar 72 as noted above. The bearing collar 72 may be axially fixed orcaptured within a body bore 62 of the head body 52 by means of amechanical feature such as a bearing snap ring 78 that may be receivedwithin a groove 86 formed in the head body 52 as shown in FIGS. 8-13.The head body 52 may include a ridge optionally formed on a side of thehead body 52 opposite the bearing snap ring 78 and groove 86 such thatthe head body 52 may contain the bearing collar 72. The bearing collar72 may be adapted to receive a bearing sleeve 80 preferably sized andconfigured to fit within the bearing bore 76 of the spherical bearing74. The bearing sleeve 80 may include sleeve snap rings 84 and/or sleeveribs formed on one or both of opposing sides of the spherical bearing 74in order to maintain axial positioning of the bearing sleeve 80 relativeto the spherical bearing 74. The bearing sleeve 80 may extend outwardlyfrom one of axially opposing ends of the spherical bearing 74. Thebearing sleeve 80 may include a bearing sleeve bore 88 for receiving thetool sleeve 96. As can be seen in FIG. 8, the tool sleeve 96 may have athreaded cylindrical outer diameter for threadably engaging aninternally threaded portion 92 of the bearing sleeve 80. The rotation ofthe tool sleeve 96 results in axial motion of the tool 110. As indicatedabove, such axial motion facilitates the application of a down force ona fastener 166 when the guide assembly 10 is mounted to the structure168. As illustrated in FIG. 8, the bearing sleeve 80 may include one ormore flats 90 on an exterior of the bearing sleeve 80 as a means torotate the tool sleeve 96 relative to the bearing sleeve 80. Rotation ofthe tool sleeve 96 may be provided by means of the tool sleeve flange 98which may be formed on one of opposing ends of the tool sleeve 96. A jamnut 94 may be threadably coupled to the threaded tool sleeve 96 to lockthe position of the tool sleeve 96 relative to the bearing sleeve 80.

Referring still to FIG. 8, the head assembly 50 may include a drivemember 114 having a drive shaft 116 which may be rotatably inserted intothe tool sleeve bore 100. The drive member 114 may have a proximal end118 and a distal end 120. The proximal end 118 may include a recess forreceiving an internal drive such as a square drive of a conventionalratchet wrench 160 or other drive mechanism for rotating the drivemember 114. The distal end 120 of the drive member 114 may include anexternal square drive or other suitable end configuration to which anadapter 124 may be coupled. In an embodiment, the adapter 124 and screwdrive bit 128 may comprise a screw guide assembly 112. As shown in FIG.8, the tool 110 such as the screw drive bit 128 may be releasablyengaged to an end of the adapter 124 by means of a square drive formedon the adapter 124. The adapter 124 may include an internal recess forcoupling to the distal end 120 of the drive member 114. However, theadapter 124 may be altogether omitted and the tool 110 may be directlycoupled to the drive member 114. A ball 122 and detent 126 mechanism maybe provided in any one of the interfaces between the drive member 114,adapter 124 and tool 110 to maintain engagement therebetween.

Referring to FIG. 9, shown is a sectional illustration of the headassembly 50 illustrating the drive member 114 mounted within the toolsleeve 96 which, in turn, is threadably coupled to the bearing sleeve80. The bearing sleeve 80 may be axially fixed relative to the sphericalbearing 74 but may be rotatably adjustable in relation to the sphericalbearing 74. The adapter 124 and/or the tool 110 are preferably sized andconfigured to fit within the bearing sleeve 80. For example, the adapter124 and/or the tool 110 may have an outer diameter which is preferablyno larger than an inner diameter of the internally threaded portion 92of the bearing sleeve 80. In this manner, rotation of the tool sleeve 96may draw the adapter 124 and/or tool 110 upwardly into the bearingsleeve 80. However, by maintaining the outer diameters of the tool 110and adapter 124 less than the inner diameter of the threaded portion ofthe bearing sleeve 80, the adapter 124 and tool 110 may be axially movedthrough the entire length of the bearing sleeve 80. Such an arrangementmay facilitate installation of the adapter 124 and tool 110 into thebearing sleeve 80. However, the outer dimensions of the adapter 124and/or tool 110 may be larger than the inner dimension of the bearingsleeve 80 such that attachment of the adapter 124 and/or tool 110 to thedrive member 114 must be performed on a side of the head assembly 50opposite the drive member 114 (i.e., below the head assembly) when theframe assembly 12 is mounted to the structure 168 as illustrated in FIG.9.

Referring still to FIG. 9, shown is the tool 110 which is illustrated asa screw drive bit 128. The screw drive bit 128 may have a fastener bitconfiguration adapted to engage drive recesses such as a Phillips, slot,Torx, Allen, etc. which may be formed in a fastener 166 head of afastener 166. In this manner, the guide assembly 10 may be employed forinstallation and removal of fasteners 166. In this regard, installationor removal of a fastener 166 may be facilitated with the use of aratchet or wrench 160 or any other suitable tool 110 engaging the drivemember 114. For example, the ratchet wrench 160 illustrated in FIG. 9may include a square drive for engaging the internal recess in theproximal end 118 of the drive member 114.

Installation of the fastener 166 into the structure 168 as illustratedin FIG. 9 may be facilitated by threadably engaging the tool sleeve 96into the bearing sleeve 80 by rotating the tool sleeve flange 98 byhand/or by using an appropriate fixture. The tool sleeve flange 98 mayinclude flats, knurls, or other features which may facilitate graspingand rotating the tool sleeve flange 98. As can be seen, rotation of thetool sleeve 96 in a clockwise direction results in axial movement of thetool 110 away from the head assembly. The adapter 124 may include anupper circumferential edge which may bear against a lower edge of thetool sleeve 96. In this manner, the down force is transmitted betweenthe lower end of the tool sleeve 96 and the adapter 124 and between theadapter 124 and the tool 110. In an embodiment, the drive member 114 isfreely rotatable within the tool sleeve 96. The drive member 114 may benon-rotatable while the tool sleeve 96 is rotated in order to axiallymove the tool 110 into engagement with the fastener 166 without rotatingthe tool 110.

Following engagement of a tip of the tool 110 with the fastener 166drive recess as shown in FIG. 9, the drive member 114 may then berotated in unison with the tool sleeve 96 in order to threadably engagethe fastener 166 into the fastener hole 176. Conversely, to remove thefastener 166 from the fastener hole 176, the drive member 114 and thetool sleeve 96 may be rotated in unison in a counterclockwise direction.However, the down force applied to the fastener 166 may be controlled byholding the tool sleeve 96 stationary while rotating the drive member114 or by rotating the tool sleeve 96 at a slower rate than the rate atwhich the drive member 11 is rotated. Increasing amounts of down forcemay be applied by maintaining the tool sleeve 96 in a non-rotatingmanner while the drive member 114 is rotated when removing the fastener166 from the fastener hole 176.

Increasing amounts of down force may be desirable for removing frozenfasteners 166 to maintain engagement of the tool 110 tip with thefastener 166. In an embodiment, the guide assembly 10 may facilitate theapplication of the down force of up to 300 pounds or greater. As may beappreciated, the magnitude of the down force is dependent at least inpart upon the strength of the attachment between the clamping assemblies34 and the structure 168. The magnitude of the down force may beproportional to the collective magnitudes of the suction forces at eachone of the vacuum cup assemblies 42. For magnet assembly 44configurations of the clamping assemblies 34, the magnitude of the downforce may be dependent upon the magnitude of the attraction with thestructure 168 to which the frame assembly 12 is attached. Other factorsaffecting the magnitude of the down force include the general stiffnessand strength of the frame assembly 12.

Referring to FIG. 10, shown is a sectional illustration of the headassembly 50 wherein the tool sleeve 96 includes a drill guide 130 thatmay be sized and configured to accept a drill bit 164 for forming anengagement hole 178 in the fastener 166 or a fastener hole 176 in astructure 168. As can be seen, the drill guide 130 may include a guideflange 134 for engagement with the tool sleeve flange 98 of the toolsleeve 96. Although the drill guide 130 is illustrated as having alength that results in a spacing between an end of the drill guide 130and the surface 170, the drill guide 130 may alternatively be providedin a length that extends to the surface 170 as shown in FIG. 14. Byproviding the drill guide 130 in a length that contacts the surface 170into which the hole is to be formed, a down force may be applied to thesurface 170 while drilling the hole which may stabilize the structure168 into which the hole is drilled.

For example, as illustrated in FIG. 14, the structure 168 may comprise afirst element 172 disposed in layered arrangement to a second element174. The fastener 166 may extend through the first and second elements172, 174. By providing the drill guide 130 in a length that contacts thesurface 170, the first element 172 and second element 174 may resistspreading apart adjacent the fastener hole and drawing in burrs or chipsgenerated by the drilling process. By apply the down force to the firstand second elements 172, 174 using the end of the tool sleeve 96/drillguide 130, the tendency of the first and second elements 172, 174 todevelop a spacing that may draw in chips is reduced. In addition, byproviding the drill guide 130 in a length that may be placed incontacting relation with the surface 170, bending of an unsupportedportion of the drill bit 164 may be reduced. In this regard, the drillguide 130 may improve the locational accuracy by which holes may bedrilled. The drill guide 130 may be sized to fit within the tool sleeve96 as shown in FIG. 10. Alternatively, the tool sleeve 96 may beconfigured as the drill guide 130 and may be directly engaged to thebearing sleeve 80 as shown in FIG. 14.

Referring to FIGS. 11-13, shown is a sequence of operations during whicha fastener 166 may be removed using the guide assembly 10. In theembodiment illustrated in FIG. 11, the tool sleeve 96 may be rotated ina clockwise manner (i.e., for right-hand threads) in order to axiallymove the tool 110 downwardly away from the head assembly 50 and intoengagement with an engagement hole 178 which may be formed in thefastener 166. As was earlier mentioned, the engagement hole 178 may beformed using a drill guide 130 placed in the tool sleeve 96 as shown inFIG. 10. Referring to FIG. 12, shown is the tool 110 engaged to theengagement hole 178 of the fastener 166 due to the rotation of the toolsleeve 96 relative to the bearing sleeve 80 and resulting axial movementof the tool 110. In this regard, FIG. 12 illustrates initiation ofremoval of the fastener 166 after the tool 110 is engaged to theengagement hole 178. In this regard, rotation of the drive member 114results in rotation of the fastener 166 for removal from the fastenerhole 176. If the tool sleeve 96 is maintained in non-rotating relationto the drive member 114 or reduced rotation relative to the drive member114 while the drive member 114 is rotated, the down force on thefastener 166 will increase as the fastener 166 moves upwardly out of thefastener hole 176. In this manner, the down force may be regulated inorder to maintain engagement of the tool 110 with the fastener 166. Thetool sleeve 96 and drive member 114 may also be rotated in unison toremove the fastener 166 from the fastener hole 176 without increasingthe down force.

FIG. 13 illustrates disengagement of the threaded fasteners 166 from thefastener hole 176 by rotation of the drive member 114. As can be seen,the jam nut 94 that is threadably coupled to the tool sleeve 96 and mayrotate with the tool sleeve 96 during the fastener 166 removal process.The fastener 166 may be removed from the tool 110 and a replacementfastener 166 may be inserted using conventional methods. As indicatedabove, the tool 110 may be provided in a variety of configurations. Forexample, the tool 110 may be provided as a screw drive bit 128configured as an extractor bit for extracting a fastener 166 frozen inposition. The tool 110 may also be provided as a fastener bit forinstalling and/or removing a fastener 166 by engaging the tool 110 to adrive recess formed in the fastener 166 or by using external features ofthe fastener 166 such as a socket drive coupled to a hex-shaped fastenerhead. In addition, the tool 110 may be configured as a removable drillguide 130 sized and configured to receive a drill bit 164 mounted in adrill gun 162 for drilling an engagement hole 178 in the fastener 166 asillustrated in FIG. 10 and/or for drilling a fastener hole 176 in thestructure 168 as illustrated in FIG. 14.

Referring to FIG. 15 and with additional reference to FIGS. 1-14, shownis a flow diagram illustrating a methodology for engaging a fastener 166that may be mounted in a structure 168. The method may comprise step 200of attaching the guide assembly 10 to the structure 168. As describedabove, the tool 110 is axially movable relative to the head assembly 50to exert the down force on the structure 168 when the frame assembly 12is attached to the structure 168. The guide assembly 10 may include theframe assembly 12 having one or more arms (e.g., first and second arms14, 16) to facilitate attachment of the frame assembly 12 to thestructure 168. The arms may be adjustably positioned relative to oneanother in any one of a variety of tube angles θ_(t) such as that whichis illustrated in FIG. 3. In this regard, the step of attaching theguide assembly 10 to the structure 168 may further comprise looseningthe swivel mechanism 18 by rotating the swivel handle 32 such that thefirst and second arms 14, 16 are freely pivotable relative to oneanother. The method may then comprise adjusting an orientation of thefirst and second arms 14, 16 relative to one another to facilitateattachment of the frame assembly 12 to the structure 168. The method mayfurther include tightening or clamping the swivel mechanism 18 in orderto lock the orientation of the first arm 14 relative to the second arm16 by rotating the swivel handle 32 to clamp the first and second arms14, 16 between the upper, intermediate and lower fittings 26, 28, 30 asillustrated in FIG. 9.

Referring still to FIG. 15, the methodology of engaging a fastener 166with the tool 110 using the guide assembly 10 may further compriseloosening or disengaging the clamping mechanisms connecting the clampingassemblies 34 to the first and/or second arms 16. The step of attachingthe guide assembly 10 to the structure 168 may comprise loosening theclamp mechanism 40 such that the clamp mechanism 40 is adjustablyorientatable relative to one of the first and second arms 14, 16. Thestep may further comprise adjusting the orientation of the clampingassemblies 34 such that each one of the clamping assemblies 34 ispreferably substantially aligned with the surface 170. In this regard,the clamping assemblies 34 are preferably oriented to be co-planar withthe surface 170. For contoured surfaces, the method may compriseorienting the clamping assemblies 34 to be substantially parallel to atangent of a contoured surface 170. Upon adjusting the orientation ofthe clamping assemblies 34, the step may further comprise tightening themounting of the clamping mechanisms 40 in order to lock the orientationof the clamping assemblies 34 relative to the first and second arms 14,16.

Upon positioning of the vacuum assemblies and/orientation of the firstand second arms 14, 16 relative to one another, the step of attachingthe guide assembly 10 to the structure 168 may further comprise applyinga vacuum to the vacuum cup assembly 42 configuration of the clampingassembly 34. In this manner, a suction force is applied to the surface170 by the vacuum cup assemblies 42 in order to attach the guideassembly 10 thereto. For the magnetic assembly 44 configuration of theclamping assembly 34 as illustrated in FIGS. 4 and 5, the step ofattaching the guide assembly 10 to the structure 168 may compriseapplying an electric current to each one of the electromagnets 48 of themagnetic assemblies 44 in order to magnetically attract the magneticassemblies 44 to the structure 168. As was indicated above, thestructure 168 is preferably fabricated of ferrous (e.g., metallic)material or any other magnetically attractable material.

Referring still to FIG. 15, step 202 may comprise aligning the headassembly 50 with the fastener 166 after or during attachment of theguide assembly 10 to the structure 168. As indicated above, the headassembly 50 may include the bearing assembly 70 such as the sphericalbearing 74 contained within the bearing collar 72 of the bearing body asillustrated in FIGS. 7-14. The orientation of the spherical bearing 74may be adjusted by loosening the clamping force exerted thereupon by thehead body 52. More specifically the head handle 54 may then be rotatedto clamp the orientation of the spherical bearing 74. In this manner,and with reference to FIGS. 9-14, the head assembly 50 may be alignedwith the fastener 166 or with the surface 170 by aligning the tool axis104 of the tool 110 with the fastener axis 180 of the fastener 166. Inthis regard, the spherical bearing 74 may be rotated within the bearingcollar 72 until the tool axis 104 is substantially aligned with thefastener axis 180.

Step 204 may comprise engaging the tool 110 to the engagement hole 178of the fastener 166. As described above, the head assembly 50 includesthe tool sleeve 96 which may be threadably coupled to the head assembly50 such that rotation of the tool sleeve 96 relative to the headassembly 50 causes relative axial movement therebetween. In this manner,the tool 110 may be axially moved away from the head assembly 50. Inorder to engage the tool 110 to the engagement hole 178 of the fastener166, the tool sleeve 96 may be rotated relative to the head assembly 50as shown in FIG. 11 until the tool 110 engages the engagement hole 178formed in the fastener 166 as illustrated in FIG. 12. Step 206 maycomprise applying the down force to the fastener 166 by moving the tool110 axially relative to the head assembly 50. The down force may beincreased by increasingly rotating the tool sleeve 96 relative to thehead assembly 50. For example, for configurations of the tool 110adapted for removing the fastener 166, the tool 110 may be sized andconfigured as an extractor bit as shown in FIGS. 11-13. The down forcemay be developed by rotating the tool sleeve 96 relative to the headassembly 50 in order to embed or engage teeth of the extractor bit intothe inner diameter of the engagement hole 178 in the fastener 166. Thefastener 166 may then be removed by rotating the tool sleeve 96 in acounterclockwise direction in combination with rotation of the drivemember 114 as illustrated in FIG. 13.

Referring to FIG. 16 and with additional reference to FIGS. 1-14, shownis a flow diagram illustrating the methodology of drilling (i.e., boringor forming) a fastener hole 176 in a structure 168. The method comprisesstep 220 of attaching the guide assembly 10 to the structure 168 asdescribed above. Step 222 may comprise inserting a drill guide 130 intothe head assembly 50. The drill guide 130 may be configured asillustrated in FIG. 10 and may be inserted into the tool sleeve 96. Thedrill guide 130 may be provided in any length including a lengthsufficient to contact the surface 170. In an embodiment, the drill guide130 may comprise the tool sleeve 96 wherein the tool sleeve 96 (i.e.,drill guide 130) is threadably coupled to the bearing sleeve 80 asillustrated in FIG. 14. The drill guide 130 (i.e., tool sleeve 96) mayextend completely through the bearing sleeve 80 and may contact thesurface 170 of the structure 168 into which the fastener hole 176 is tobe drilled or formed. A down force may be applied by rotating the toolsleeve 96 (i.e., drill guide 130) to force the drill guide 130 againstthe surface 170. Step 224 may comprise aligning the drill guide 130substantially with a predetermined hole location 184. For example, asillustrated in FIG. 14, the frame assembly 12 may be mounted such thatthe drill guide 130 is centered on a predetermined hole location 184. Inaddition, the drill guide 130 may be substantially aligned with the holeaxis of the fastener hole 176 at the predetermined hole location 184 byloosening the spherical bearing 74 and adjusting the orientationthereof. Step 226 may comprise drilling the fastener hole 176 at thepredetermined hole location 184 such as illustrated in FIGS. 10 and 14.

Referring to FIG. 17, shown is a flow chart illustrating a methodologyof removing a fastener 166 mounted in a structure 168. The method maycomprise step 240 of attaching the guide assembly 10 to the structure168 in the manner as described above with reference to the flow chart ofFIG. 15. The guide assembly 10 includes the head assembly 50 which hasthe tool sleeve 96 coupled to the spherical bearing 74. The tool sleeve96 may be axially movable relative to the spherical bearing 74. Step 242may comprise inserting the drill guide 130 into the tool sleeve 96 inthe manner illustrated in FIG. 10. The drill guide 130 preferably has anouter diameter that is sized to be complementary to an inner diameter ofthe tool sleeve 96. Likewise, the drill guide 130 preferably has aninner diameter that is preferably sized and configured complementary toan outer diameter of the drill bit 164. In an embodiment, the toolsleeve 96 may comprise the drill guide 130 as illustrated in FIG. 14such that the drill guide 130 is threadably coupled to the bearingsleeve 80.

Step 244 may comprise aligning the tool sleeve 96 or drill guide 130with the fastener 166 by rotating the spherical bearing 74. In a manneras indicated above, the tool sleeve 96 or drill guide 130 may beoriented into substantial alignment with the fastener 66 by looseningthe head handle 54, orienting the tool sleeve 96 or drill guide 130 intoalignment with the fastener 166, and then rotating the head handle 54 inorder to tighten the head body 52 around the spherical bearing 74 toprevent rotation thereof. Step 246 may comprise drilling the engagementhole 178 in the fastener 166 as illustrated in FIG. 10. For example, anoperator may insert a drill bit 164 into the drill guide 130 as shown inFIG. 10 to drill the engagement hole 178 in the fastener 166. Theengagement hole 178 is preferably centered in the fastener 166 in orderto prevent breakout of the drill bit 164 into a side of the fastener 166which may damage the threaded bore (i.e., fastener hole 176) into whichthe fastener 166 is mounted. In addition, the tool axis 104 ispreferably substantially aligned (i.e., parallel with) the fastener axis180.

Step 248 comprises removing the drill guide 130 from the tool sleeve 96.The methodology may comprise installing the drive member 114 in the toolsleeve 96 in step 250 as illustrated in FIG. 11. As indicated above, thedrive member 114 includes distal and proximal ends 118, 120 with thedistal end 120 being coupled to the adapter 124 which, in turn, may becoupled to the tool 110. Alternatively, the tool 110 may be directlycoupled to the drive member 114 such as by engagement of a square driveon the distal end 120 of the drive member 114 to an internal recesssquare drive formed in the tool 110. In this regard, step 252 comprisescoupling the tool 110 to an end of the drive member 114 such as to theproximal end 118 thereof. Ball and detents as shown in FIG. 8 or othersuitable mechanisms, if included, may maintain attachment of the drivemember 114 to the adapter 124 and attachment of the adapter 124 to thetool 110. Step 254 comprises engaging the tool 110 to the engagementhole 178 of the fastener 166 as illustrated in FIG. 12. As indicatedabove, the tool sleeve 96 is preferably threadably coupled to thespherical bearing 74 such that the tool sleeve 96 may be moved axiallyrelative to the spherical bearing 74 in step 256 in a manner to causeaxial movement of the tool 110.

The drive member 114 may be freely rotatable relative to the tool sleeve96 such that the tool sleeve 96 may be axially moved independent ofrotation of the tool 110. Increasing amounts of down force may beapplied to the fastener 166 via the tool 110 by holding the drive member114 in non-rotating relation to the tool sleeve 96. More specifically,by rotating the tool sleeve 96 while holding the drive member 114stationary, the tool 110 may be extended further away from the headassembly 50 resulting in an increasing amount of down force applied tothe fastener 166. In this manner, the teeth of the screw drive bit 128or screw extractor bit may be engaged to the material along the innerdiameter of the engagement hole 178 in the fastener 166. Removal of thefastener 166 may be facilitated by rotating the screw extractor bitwhile simultaneously rotating the tool sleeve 96. The rotation of thetool 110 and tool sleeve 96 may also be performed in such a manner thatdown force may be continuously applied to the tool 110. Furthermore, byrotating the tool sleeve 96 at a slower rate than the rate at which thedrive member 114 is rotated, a gradually decreasing amount of down forcemay be applied on the fastener 166 as the fastener 166 is removed.

Referring to FIGS. 18-19, embodiments of the disclosure may be describedin the context of an aircraft manufacturing and service method 300 asshown in FIG. 18 and an aircraft 302 as shown in FIG. 19. Duringpre-production, exemplary method 300 may include specification anddesign 304 of the aircraft 302 and material procurement 306. Duringproduction, component and subassembly manufacturing 308 and systemintegration 3 10 of the aircraft 302 takes place. Thereafter, theaircraft 302 may go through certification and delivery 312 in order tobe placed in service 314. While in service by a customer, the aircraft302 is scheduled for routine maintenance and service 316 (which may alsoinclude modification, reconfiguration, refurbishment, and so on).

Each of the processes of method 300 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof vendors, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 19, the aircraft 302 produced by exemplary method 300may include an airframe 318 with a plurality of systems 320 and aninterior 322. Examples of high-level systems 320 include one or more ofa propulsion system 324, an electrical system 326, a hydraulic system328, and an environmental system 330. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of thedisclosed embodiments may be applied to other industries, such as theautomotive industry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 300. Forexample, components or subassemblies corresponding to production process308 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 302 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 308 and 310, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 302. Similarly, one or more of apparatus embodiments, methodembodiments, or a combination thereof may be utilized while the aircraft302 is in service, for example and without limitation, to maintenanceand service 316

Additional modifications and improvements of the present disclosure maybe apparent to those of ordinary skill in the art. Thus, the particularcombination of parts described and illustrated herein is intended torepresent only certain embodiments of the present disclosure and is notintended to serve as limitations of alternative embodiments or deviceswithin the spirit and scope of the disclosure.

What is claimed is:
 1. A method of engaging a fastener, comprising thesteps of: attaching a guide assembly to a structure, the guide assemblyincluding a first arm, a second arm, and a head assembly mounted to anend of the first arm; threadably engaging a tool sleeve to the headassembly; coupling a tool to the tool sleeve; adjusting, using a swivelmechanism, an angular orientation of the second arm relative to thefirst arm; clamping the first arm to the second arm using the swivelmechanism; engaging the tool to the fastener; rotating the tool sleeverelative to the head assembly; and applying a down force to the fastenerin response to rotating the tool sleeve to move the tool axiallyrelative to the head assembly.
 2. The method of claim 1 furthercomprising the step of: rotating the tool while applying the down forceto remove the fastener.
 3. The method of claim 1 wherein, the step ofapplying the down force to the fastener comprises: rotating the toolsleeve relative to the head assembly to axially move the tool away fromhead assembly.
 4. The method of claim 1 further comprising the step of:aligning the head assembly with the fastener.
 5. The method of claim 4wherein the tool and the fastener respectively define a tool axis and afastener axis, the head assembly including a spherical bearing havingthe tool coupled thereto, the step of aligning the head assembly withthe fastener comprising: rotating the spherical bearing until the toolaxis is substantially aligned with the fastener axis.
 6. The method ofclaim 1 wherein the guide assembly includes at least one vacuum cupassembly mountable to a surface of the structure, the step of mountingthe guide assembly to the structure comprising: applying a vacuum to thevacuum cup assembly to attach the guide assembly to the surface.
 7. Themethod of claim 1 wherein the guide assembly includes at least onemagnet assembly configured as an electromagnet, the step of attachingthe guide assembly to the structure comprising: applying an electriccurrent to the electromagnet to attach the guide assembly to thestructure.
 8. The method of claim 1 wherein the first and second armseach have at least one clamping assembly mounted thereto, the step ofattaching the guide assembly to the structure comprising: adjusting anorientation of the clamping assemblies such that the clamping assembliesare substantially aligned with the structure.